Composite textured products and their manufacture

Abstract

A technique for the manufacture of synthetic sheet material having a textured surface and suited for use as floor or wall covering. The technique in accordance with the invention includes the printing of a decoration on a support member and the applying of a transparent plastisol in the form of a discontinuous layer over and in accordance with the decoration. The invention also contemplates the application of a continuous wear layer which, in the final product, will either be disposed between the discontinuous transparent plastisol and the decoration or will cover the discontinuously applied plastisol which provides the textured effect.

What is claimed is: 
     
       1. A process for the manufacture of sheet material having a relief effect on at least a first surface comprising the steps of: printing a decoration on a surface of a support member;   applying at least one discontinuous layer of a transparent plastisol over and in registration with at least part of the printed decoration, the plastisol being applied in a thickness of at least ten mils and imparting a desired relief appearance to the printed decoration, the decoration being viewed through the discontinuous layer of plastisol; and   passing the printed plastisol bearing support through a gelation oven.   
     
     
       2. A process as claimed in claim 1 wherein the application of the transparent plastisol is performed by silk screen printing. 
     
     
       3. A process as claimed in claim 2 further comprising the step of: forming a continuous wear layer over the transparent plastisol before passage through the gelation oven.   
     
     
       4. A process as claimed in claim 3 wherein the decoration is printed on a deformable support and said process further comprises the step of: laminating the deformable support to a temperature stable support before passage through the gelation oven.   
     
     
       5. A process as claimed in claim 2 further comprising the step of: forming a continuous wear layer over the transparent plastisol after passage through the gelation oven.   
     
     
       6. A process as claimed in claim 5 wherein the decoration is printed on a deformable support and said process further comprises the step of: laminating the deformable support to a temperature stable support before passage through the gelation oven.   
     
     
       7. A process as claimed in claim 2 wherein the printing of the decoration on the support is performed by a heliographic method. 
     
     
       8. A process claimed in claim 7 further comprising the step of: forming a continuous wear layer over the transparent plastisol after passage through the gelation oven.   
     
     
       9. A process as claimed in claimed 1 further comprising the step of: forming a continuous wear layer over the transparent plastisol after passage through the gelation oven.   
     
     
       10. A process as claimed in claim 9 wherein the formation of the wear layer is accomplished by coating a continuous, thin and uniform layer of a plastisol by means of an air-knife coater. 
     
     
       11. A process as claimed in claim 9 wherein the formation of the wear layer is accomplished by laminating a transparent calendered sheet to the product exiting the oven. 
     
     
       12. A process as claimed in claim 9 wherein the formation of the wear layer is accomplished by curatin coating. 
     
     
       13. A process as claimed in claim 1 for further comprising the step of: forming a continuous wear layer over the transparent plastisol before passage through the gelation oven.   
     
     
       14. A process as claimed in claim 13 wherein the formation of the wear layer is accomplished by curtain coating. 
     
     
       15. A process as claimed in claim 1 wherein the decoration is, printed on a deformable support and said process further comprises the step of: laminating the deformable support to a temperature stable support before passage through the gelation oven.   
     
     
       16. A process as claimed in claim 1 further comprising the step of: laminating at least one layer to the product exiting from the gelation oven to impart desired non-visual characteristics to the sheet material.   
     
     
       17. A process as claimed in claim 1 wherein the transparent plastisol is applied in a thickness within the range of 0.2 to 0.4 mm. 
     
     
       18. A process as claimed in claim 17 wherein the support member is at least in part comprised of an expandable layer and wherein said process further comprises the step of: subjecting the printed plastisol bearing support to a further heating step to cause expansion of the expandable portion of the support to form a cellular layer.   
     
     
       19. A process as claimed in claim 1 wherein the support member is at least in part comprised of an expandable layer and wherein said process further comprises the step of: subjecting the printed plastisol bearing support to a further heating step to cause expansion of the expandable portion of the support to form a cellular layer.   
     
     
       20. An article produced in accordance with the process of claim 1.